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1 7500 SERIES 3-1/4 PEK HP ROUTERS Série 7500 Toupies de 3-1/4 hp de pointe Serie 7500 Rebajadoras de 3-1/4 HP máximos Instruction manual Manuel d'instructions Manual de'instrucciones TO REDUCE THE RISK OF INJURY, USER MUST RED INSTRUCTION MNUL EFORE OPERTING PRODUCT. PR REDUCIR EL RIESGO DE LESIONES, EL USURIO DEE LEER EL MNUL DE INSTRUCCIONES NTES DE OPERR EL PRODUCTO FIN DE RÉDUIRE LE RISQUE DE LESSURES, L UTILISTEUR DOIT LIRE LE MODE D EMPLOI VNT D UTILISER LE PRODUIT. Part No Rev. DEFINITIONS - SFETY GUIDELINES indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. indicates a potentially haz ard ous situation which, if not avoided, may result in minor or mod er ate injury. used without the safety alert symbol indicates potentially hazardous situation which, if not avoided, may result in property damage. General Safety Rules Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term power tool in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. SVE THESE INSTRUCTIONS 7518/ / Copyright 2007 Porter-Cable 1) Work area safety a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. 2) Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use anyadapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) void body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool s plug. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. If an extension cord is to be used outdoors, it must be marked with the suffix W- or W following the cord type designation. Use of a cord suitable for outdoor use reduces the risk of electric shock. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. n undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. Minimum Gauge for Cord Sets Volts Total Length of Cord in Feet 120V V mpere Rating Gauge of wire in WG units From 12 to 16 amps Not recommended 3) Personal safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. moment of inattention while operating power tools may result in serious personal injury. b) Use safety equipment. lways wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c) void accidental starting. e sure the switch is in the off-position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. ir vents often cover moving parts and should also be avoided. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dustrelated hazards. 4) Power tool use and care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. ny power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. 5) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. DDITIONL SPECIFIC SFETY RULES Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a live wire will make exposed metal parts of the tool live and shock the operator. Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control. Metal cutting with router: If using router for metal cutting, clean out tool often. Metal dust and chips often accumulate on interior surfaces and could create a risk of serious injury, electrical shock or death. Keep handles dry, clean, and free from oil and grease. This will enable better control of the tool. Maintain firm grip with both hands on router to resist starting torque. Keep hands away from cutting area. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting. Hold the router only by the handles. These precautions will reduce the risk of personal injury. Do not hand-hold the router in an upside-down or horizontal position. The motor can separate from the base if not properly attached according to the instructions. Never run the motor unit when it is not inserted in one of the router bases. The motor is not designed to be handheld. Keep cutting pressure constant. Do not overload motor. Check to see that the cord will not snag or impede the routing operation. Use sharp cutters. Dull cutters may cause the router to swerve or stall under pressure. e sure that the motor has stopped completely before you lay the router down. If the cutter head is still spinning when the tool is laid down, it could cause injury or damage. e sure that the router bit is clear of the workpiece before starting the motor. If the bit is in contact with the workpiece when the motor starts it could make the router jump, causing damage or injury. LWYS disconnect tool from power source before making adjustments or changing bits. Keep hands clear of bit when motor is running to prevent personal injury. NEVER touch the bit immediately after use. It may be extremely hot. Provide clearance under workpiece for router bit when through-cutting. Tighten collet nut securely to prevent the bit from slipping. Never tighten collet nut without a bit. Do not use router bits with a diameter in excess of 2-1/2" at RPM above 13,000. Router bits up to 3-1/2" in diameter can be used when speed control is set for 13,000 RPM or less. void Climb-Cutting (cutting in direction opposite that shown in Fig. 16). Climb-Cutting increases the chance for loss of control resulting in possible injury. When Climb-Cutting is required (backing around a corner), exercise extreme caution to maintain control of router. Make smaller cuts and remove minimal material with each pass. lways keep chip shield clean and in place. LWYS USE SFETY GLSSES.(NSI Z87.1) and (CN/CS Z94.3) Everyday eyeglasses are NOT safety glasses. lso use face or dust mask if cutting operation is dusty. LWYS WER CERTIFIED SFETY EQUIPMENT: NSI Z87.1 eye protection (CN/CS Z94.3) NSI S12.6 (S3.19) hearing protection NIOSH/OSH/MSH respiratory protection Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: lead from lead-based paint. crystalline silica from bricks and cement and other masonry products. arsenic and chromium from chemically-treated lumber (CC). Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. void prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. llowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals. Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. lways use NIOSH/OSH approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. LWYS use eye protection. ll users and bystanders must wear eye protection that conforms to NSI Z87.1. Wear appropriate hearing protection during use [NSI S12.6 (S3.19)]. Under some conditions and duration of use, noise from this product may contribute to hearing loss. SYMOLS The label on your tool may include the following symbols. The symbols and their definitions are as follows: V... volts...amperes Hz... hertz W...watts min... minutes...alternating current... direct current no...no load speed... Class I Construction...earthing terminal (grounded)...safety alert symbol... Class II Construction /min...revolutions or reciprocations (double insulated) per minute PM...beats per minute SVE THESE INSTRUCTIONS MOTOR Do not operate your tool on a current on which the voltage is not within correct limits. Do not operate tools rated.c. only on D.C. current. To do so may seriously damage the tool. OPERTION FMILIRIZTION Model 7518/ Porter-Cable routers incorporate a speed control that provides operating speeds from 10,000 RPM to 21,000 RPM. Model 7519/7538 Porter-Cable Routers are designed for opearations at 21,000 RPM. SELECTING THE IT (LL UNITS) To reduce the risk of personal injury, always disconnect tool from power source before preparing the router for use, before making adjustments, and when router is not in use. 2-1/2". For the 7519 and 7538, DON T USE router bits with a cutting diameter in excess of For the variable speed units (7518 and ), bits larger than 2-1/2 can be used when running the router at lower speeds. If the bit is between 2-1/2 and 3, you can only use the 10,000 or 13,000 RPM speed settings. If the bit is between 3 and 3-1/2, you can only use the 10,000 RPM speed setting. ll 7500 Series routers accommodate bits with 1/2" diameter shanks that are installed directly into the power unit collet. Collets are available that will allow the use of bits having 1/4" or 3/8" diameter shanks. INSTLLING ND REMOVING THE IT (7518 / 7519) before installing and removing accessories, before adjusting or when making repairs. n For the 7519 and 7538, DON T USE router bits with a cutting diameter in excess of 2-1/2". void possible damage to the collet. Never tighten the collet without a bit. 1. To remove motor unit from base unit: (a) Open the clamp () Fig. 1. (b) While holding base, turn motor unit COUNTERCLOCKWISE until lower pin () in motor housing is disengaged from groove in base. (c) Lift power unit free from base unit. 2. Clean and insert shank of bit into collet at least 3/4". If shank bottoms in router, then back it out approximately 1/16" to allow proper tightening. 3. Lay the power unit on its side on a bench with the collet pointing WY from you. 4. Place one wrench on flats on chuck with the opposite end of the wrench resting on the bench to your left, Fig Place other wrench on collet and tighten COUNTERCLOCKWISE as shown in Fig. 2. TIGHTEN SECURELY. 6. To remove the bit, reverse the above procedure. If bit does not remove easily, tap the collet nut with wrench to release. INSTLLING ND REMOVING THE IT (7538 / ) before installing and removing accessories, before adjusting or when making repairs. n

2 Fig. 1 Fig. 4 F D C Fig. 2 Fig. 3 J K R E H L M C MODEL 7518 Fig. 7 S Fig. 5 Fig. 6 P MODEL 7519 O V T Fig. 9 Fig. 10 Fig. 11 Fig. 13 Fig. 12 Do not allow the wrenches to contact the columns () Fig. 3. If the columns are damaged, the plunge action will be restricted. For the variable speed units (7518 and ), bits larger than 2-1/2 can be used when running the router at lower speeds. If the bit is between 2-1/2 and 3, you can only use the 10,000 or 13,000 RPM speed settings. If the bit is between 3 and 3-1/2, you can only use the 10,000 RPM speed setting. void possible damage to the collet. Never tighten the collet without a bit. 1. Place the router upside down on its motor cap (see Fig. 3). 2. Clean and insert the shank of the bit into the collet at least 3/4". If the shank "bottoms" in the router, back it out approximately 1/16" to allow for proper tightening. 3. Place one wrench on the flats on the chuck and one wrench on the collet nut (see Fig. 3). Tighten firmly. 4. To remove the bit, reverse the procedure. If the bit is difficult to remove easily, tap the collet nut with the wrench. INSTLLING THE MOTOR (7518 / 7519) To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. n 1. Loosen the clamp screw (), Fig. 1, to allow the power unit to be set in the base unit. 2. Insert motor unit into base aligning lower pin () with groove in base. 3. Rotate motor unit CLOCKWISE into base until upper guide pins are rigidly set in the groove of the base. 4. Tighten clamp screw firmly. DJUSTING THE DEPTH OF CUT (7518 / 7519) D To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. n Fig Loosen clamp screw () Fig While holding base (E), turn motor unit (F), COUNTERCLOCKWISE until the tip of the bit is above bottom surface of base. 3. Set router on flat wood surface. 4. Turn motor unit (F) CLOCKWISE until bit touches the wood surface. 5. Tighten clamp screw (). 6. Rotate depth adjusting ring () until the zero-line (C) is opposite the index line (D) on the housing. 7. Loosen clamp screw (). 8. Tip the router so bit is clear of the wood surface. Turn motor unit (F), CLOCKWISE until the index line (D) on the motor housing reaches the desired depth indicated on the ring. 9. Tighten clamp screw () firmly. NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed 1/4" below the base. DJUSTING PLUNGE DEPTH (7538 / ) before installing and removing accessories, before adjusting or when making repairs. n Laceration hazard. Do not change the turret stop while the router is running. This will place your hands too near the cutter head. 1. Loosen the depth rod locking knob (K) Fig. 5, and the depth indicator knob (J), allowing the depth rod (L) to contact one of the turret stops (M). Normally, the deepest desired cut is set with the depth rod resting on the shortest turret stop (see Fig. 7). The other two fixed stops (S) Fig. 9 provide reduced cutting depths of 1/4" and 1/2" respectively. You can position the three adjustable stops (R) Fig. 7 to any height and can use any combination of fixed and/or adjustable stops to achieve the desired depths required. 2. Release the plunge mechanism by pulling the locking lever (C) Fig. 6 to the left, and lower the plunge mechanism until the router bit touches the work surface. Release the lever and push it to the right to lock the mechanism in position. 3. Tighten the depth-rod locking knob (K) Fig Position the depth indicator (H) Fig. 5 at the "O" position and tighten the knob (J). 5. Loosen the depth rod locking knob (K) Fig. 5, and raise the depth rod until the indicator aligns with the graduation representing the desired depth of plunge. Tighten the depth rod locking knob (K). 6. To limit the upward travel of the plunge mechanism: (1) release the plunge lock by moving the plunge locking lever (C) Fig. 6 to the left, and move the motor to the desired maximum height; (2) release and push the locking lever (C) to the right to secure the motor in this position; (3) use two 9/16" open-end wrenches (not furnished) to move the travel-limiting nuts (O) Fig. 9 against the top of the motor housing boss (T) Fig. 9. "Jam" the nuts together to lock. To prevent loss of control LWYS tighten the travel-limiting nuts together. Inadvertant movement could prevent full bit retraction. To prevent loss of control, set the travel-limiting nuts so that bit can be retracted into the base of the router, clear of the workpiece. To reduce the risk of injury, NEVER adjust or remove the stop nut. Motor can disengage resulting in loss of control. DJUSTING PLUNGE LOCKING LEVER (7538 / ) before installing and removing accessories, before adjusting or when making repairs. n You can adjust the plunge locking mechanism to compensate for wear or to reposition lever (in locked position). To adjust: 1. Hold the lever in the upright position (see Fig. 10). Use a phillips screwdriver to remove retaining screw (V) Fig. 10. Continue to hold the lever through the remaining steps. 2. Insert a 1/8" hex wrench (not furnished) into the adjusting screw (see Fig. 11) and turn counterclockwise approximately 1/2 turn. 3. Move the lever to the desired position and tighten the adjusting screw. 4. Remove the hex wrench and replace the retaining screw. CONNECTING TO POWER SOURCE (LL UNITS) efore connecting router to power source LWYS MKE SURE SWITCH IS IN THE OFF POSITION. lso check that the power circuit is the same as that shown on specification plate of the router. TO STRT ND STOP ROUTER (7518 / 7519) efore starting the router make sure bit is clear of workpiece and foreign objects. lso keep firm grip on router to resist starting torque. The router is started and stopped by depressing the rocker switch (), Fig. 12, into the "ON" or "OFF" position. MODEL 7538 G Fig ROUTER SE 2. SU-SE 3. ROUTER IT 4. TEMPLET GUIDE 5. LOCKNUT 1. SE DE L TOUPIE 2. SOUS-SE 3. MÈCHE DE TOUPIE 4. GUIDE DE GRIT 5. CONTRE-ÉCROU Fig SE DEL REJDOR 2. SU-SE 3. ROC 4. GUI DE PTRON 5. TUERC INFLOJLE C D Fig. 15 X 7538/ 4 Fig. 16 Fig. 18 To avoid personal injury or damage to finished work always allow the motor to come to a COMPLETE STOP before setting it down. TO STRT ND STOP ROUTER (7538 / ) efore starting the router, make sure bit is clear of workpiece and foreign objects. lso keep a firm grip on the router to resist starting torque. To avoid injury or damage to finished work, allow the motor to come to a COMPLETE STOP before putting it down. 1. Squeeze the trigger switch () Fig. 13 to start the motor. Release the trigger switch to stop the motor. 2. To allow the motor to run continuously, press the trigger switch (), push the lock button () Fig. 13, and release the trigger switch. 3. To release the lock button, squeeze the trigger switch and release. OVERLOD PROTECTION (LL UNITS) To avoid accidental start-up, confirm that the switch is OFF and tool is disconnected from the power source before resetting the circuit breaker. The 7500 series routers are equipped with overload protection that will shut the motor off if prolonged overload conditions are encountered. If the motor stops during use, follow these steps: 1. Turn rocker switch (), Fig. 12, to the "OFF" position. 2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct before continuing. 3. Restart router following the instructions in "TO STRT ND STOP ROUTER." Release the trigger switch () Fig. 13 and then turn rocker switch (G) Fig. 14 on router cap to the "OFF" position. 2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct before continuing. 3. Turn rocker switch (G) Fig. 14 to the "ON" position. 4. Restart router following the instructions in "TO STRT ND STOP ROUTER." 1. Release the trigger switch () Fig Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct before continuing. 3. Turn rocker switch (G) Fig. 14 to the "ON" position. 4. Restart router following the instructions in "TO STRT ND STOP ROUTER." Y 5 3 W Z W

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